Structural arrangement for generally planar devices

ABSTRACT

A system and method for simplified construction and erection of planar devices such as walls comprises two types of steel channel members twisted together at right angles to form a tight, weldless and fastener-less connection. Slots in one member mate with flange elements of the other member to form the tight connection. Both steel members may be cold rolled from flat steel stock, the mating slots being cut into the flat steel stock prior to rolling. Though the resulting connections rely upon the strength of the steel itself instead of fasteners or welds, auxiliary screws or other fasteners optionally may be employed to prevent untwisting of the members after installation.

BACKGROUND OF THE INVENTION

1. Field of the Invention:

This invention relates generally to construction materials, and particularly to devices for use in erecting walls in buildings. More particularly, this invention relates to a system of modular wall stud and plate members which couple together tightly and easily without requiring welding or fasteners.

2. Description of Related Art:

There are many instances in which structural pieces are put together to form generally planar devices, including the building of houses. Included in modern houses are walls such as those suggested in U.S. Pat. No. 4,713,923 to Sielaff et al., and illustrated by the vertical studs 64 around the periphery of the house. To give rigidity to the house and give it the strength to withstand wind loads, the studs are commonly connected to foundation members (e.g., horizontal plates) by nails or screws to metal connecter devices. An improvement to the idea of providing durability against destructive forces such as fire, termite infestation, etc. is to use steel rather than wood for the studs. Common methods include the use of welds or screws to secure the metal studs to metal plates at the tops and bottoms of the studs. Unfortunately, welding involves the use of skilled workers and equipment that is both expensive and heavy, and is often not readily available at remote job sites. The common screw-together steel systems overcome the disadvantages of welding, but do not provide connections with rigidity.

SUMMARY OF THE INVENTION

The construction disclosed herein is an improvement on these old connection systems by incorporating steel members as a part of the walls being fabricated--but eliminating the need to weld them to other members or use metal fasteners (such as screws). In other words, by incorporating special configurations in at least one or both of the steel pieces disclosed herein, it is possible to rely to a large part on the strength of the steel being connected, and not have to depend so heavily on the strength of connecting elements such as screws.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the present invention may be set forth in appended claims. The invention itself, however, as well as a preferred mode of use and further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:

FIG. 1 shows in quartering perspective an example of the steel member connection apparatus present invention.

FIG. 2 shows in top plan view the steel member connection apparatus of FIG. 1.

FIG. 3 depicts in top plan view a series of steps in joining the steel members to produce the steel member connection of FIGS. 1 and 2.

FIGS. 4 shows in left-side elevational view the steel member connection of FIGS. 1 and 2.

FIG. 5 shows in left and right elevational end views the present invention as depicted in FIG. 4.

FIG. 6 depicts a flat steel member being roll-formed into one of the steel members of the present invention.

FIGS. 7A-7E, inclusive, depict cross sections of the steel member of FIG. 6, at points along its length, as indicated in FIG. 6.

FIG. 8 details a cut line between two successive lengths of the steel member of FIG. 6, along with slots cut in each end of successive steel members.

FIG. 9 details one of the cut slots of FIG. 8.

FIG. 10 details in close up elevational end view the connection between two steel members according to the invention of FIG. 1.

DESCRIPTION OF A PREFERRED EMBODIMENT

Referring initially to FIGS .1 and 2, there is shown a first elongated structural member 12 that will typically be positioned horizontally at the bottom of a building's walls. Extending upwardly from the horizontal member 12 will be a plurality of studs, only one of which 14 is shown in this sketch. (For clarity, the first member 12 will sometimes be described as the horizontal member, and the second member 14 will sometimes be described as the vertical member 14.)

A close inspection of FIGS. 1 and 2 will reveal that the vertical stud is slightly smaller--but only in width than, in comparison with the horizontal member 12. More precisely, the smaller stud 14 is more narrow than the larger member 12 by a distance of approximately three times the thickness of the steel in the other structural members (i.e., three times 0.075 or 0.225). This difference in size allows the horizontal piece to envelope an end of the vertical stud—and provides a modest amount of clearance for rotating the member 14 about an axis parallel to the longitudinal axis of the stud 18, by about 90 degrees, when achieving engagement of the stud with the prepared slots in said member

The prepared slots 16 in the member 14 will tightly fit over lips in the horizontal piece 12 when the member 14 is inserted into piece 12 and then rotated about ninety degrees. This rotation movement is shown in FIG. 3, where member 14 is shown as being rotated clockwise about axis 18. After appropriate rotation has been completed, the two elongated members will appear as shown in FIGS. 1, 2, 4 and 5.

An expeditious way of fabricating the elongated members 12, 14 is to use roll forming techniques, wherein a coiled roll of flat steel (e.g., 14 gauge) is pulled through a series of dies that progressively roll the sides of the steel inwardly. The slots 16 are stamped (essentially cut) into the steel while it is still flat, as indicated by FIG. 6. FIGS. 7A, 7B, 7C, 7D and 7E show the process of shaping a piece of steel as it is pulled longitudinally through a series of dies.

This mechanical interlocking of the two steel members (by twisting the end of one piece within the other) provides a relatively strong connection without the need to weld the pieces together in the field (at the job site), and can be achieved by relatively unskilled labor. Optionally, sheet metal screws can be added to hold the pieces together, so that they don't accidentally twist apart as a result of some extraneous force. All of the serious thinking, calculating, sizing, cutting and shaping can be done in the relatively clean and dry environment of a factory. Only unskilled labor is required to twist the vertical studs into engagement with the horizontal base and a similar upper plate (if desired).

FIG. 8 shows how an elongated piece of sheet metal is cut, leaving two prepared ends, ready to engage the horizontal piece of sheet metal. FIG. 9 shows an enlarged view of the cut in the vertical piece of sheet metal. It will be seen that the cut is not purely rectangular. Instead, the upper edge is lowered by about 1/16th of an inch, which leaves an extra 1/16 inch or so of metal to contact the lower piece in the region indicated by the region A in FIG. 10.

This extra metal in the vertical piece enhances the area of direct contact between first and second pieces of sheet metal, after the second piece of sheet metal has been rotated some 90 degrees with respect to the horizontal piece. Explained in other words, this dip in the upper piece of sheet metal insures that there will be full contact with the lower piece of sheet metal—as that curved metal “falls away” by virtue of the curvature of the sheet metal.

While the invention has been particularly shown and described with reference to preferred and alternate embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. 

1. In the construction industry, the art of achieving a load-bearing relationship between two pieces of sheet metal, comprising the steps of: a bending a first piece of sheet metal so that it forms a generally C-shaped channel, and the outer edges of the channel defining linear lips; b. positioning a second piece of sheet metal such that one of its two ends can be inserted into the channel of the first piece of sheet metal; c, placing a pair of slots into the second piece of sheet metal near that end that has been inserted into the channel; and d, twisting the second piece of sheet metal so that the slots in the second piece of sheet metal envelope the linear lips of the first piece of sheet metal.
 2. The method as claimed in claim 1 wherein the first and second pieces of sheet metal each have a thickness of about 14 gauge.
 3. The method as claimed in claim 1 wherein the slots that are cut into the second piece of sheet metal are about 2 and ¼ inch long.
 4. The method as claimed in claim 1 wherein the slots are located about 1 and ¼ inch from the first end of the second piece of sheet metal.
 5. The method as claimed in claim 1 wherein the slots are cut in the second piece of sheet metal while the sheet metal is still flat and before the sheet metal is bent into its channeled shape.
 6. The method as claimed in claim 1 wherein the metal is shaped into a C shape by virtue of roll forming.
 7. The method as claimed in claim 1 wherein the second piece of sheet metal is rotated by an angle of approximately 90 degrees about it's longitudinal axis in order to secure engagement with the first piece of sheet metal.
 8. The method as claimed in claim 1 wherein the first piece of sheet metal has a central web that extends longitudinally, and said central web has a transverse width of about 3 and ¾ inches.
 9. The method as claimed in claim 1 wherein a pair of sheet metal screws are inserted horizontally into the joint between the first and the second sheet metal screws, whereby relative movement between the two pieces is prohibited. 